Motor control system



July 18, 1950 H. L. RATHBUN 2,515,612

MOTOR CONTROL SYSTEM Filed Feb. 20, 1946 2 Sheets-Sheet l [N VEN TOR.

July 18, 1950 H. L. RATHBUN MOTOR CONTROL SYSTEM 2 Sheets-Sheet 2 Filed Feb. 20, 1946 HQIST LOWER 20m rH INVENTOR. 44151 Qmw m/ ii ill! 1 wlt Patented July 18, 1950 UNITED PATENT OFFICE MOTQR CONTROL SYSTEM HaroldJ Bathhun, Cleveland,- Ohio, assignor to The ElectricContnoller & Manufacturing Company, (llevelandhohio, a corporation of Ohio Application February 20, 1946, Serial N 0. 648,951

9,.Claims. 1,

This invention relates; to; a; motor control system. and'more: particularly to a control system for-adirect currentmotor. driving the hoist motion of a: crane orthe like: wherein thearmat e winding andfield windingrof-i the motora-re connected. inv series with; each othcrrfor hoist and inparallel witheachother for. normal lowering operations, and: wherein a limit: switch or limit stop is used for: automatically completing an emergency dynamic braking circuit-for themotor in event;the motonraisestheloadztoo high;

In'theoperation' of a: hoist-by, a, direct current motor; it is common practice; to control, the normal lowering operations,,;which; occur with the limit switch; in: its'normaliuntripn d po tion, y settingup-a dynamic lowering circui-t which permits; the motor either to drive-the load-as a shunt motor; on to retardithe, load as a g nerator, the weight: of the load ,alone determining the action of: the-motor. Suitable resistorsdnseries with the motor andalsodn; the fieldandarmature circuits are regulatedto' control-the speed during the normal-lowering operations. The motor is generally connected; as a; series motor; for hoistingpurposes becauseofthe 300d: speed-torque characteristics ofsuch a connection; andsomeof'thesame resistors; used,- duringlowering: areconneeted: in series with the motor; and are regulated tocontrol the hOiSting-:S1Ql3ed. In manyinstances a very slow hoistingspeed is. obtained; by; connecting. a

resistor, also used; during lowering; in parallel ziththe motor-to: providaa motor shunt connection.

It is also common practice inv suchprior hoist control systems totutilize the limit switch as a control meanstorestablishanemergencydynamic braking circuit for the motor in response to movement of the hcistbeyond-a predetermined point in-thehoisting direction. Operation of the limit switch alsodisconnecis the-motor, from-the power sourceand, except when the-motor shunt connection for slow speedhoisting; is completed, permits the usual. spring-applied, electromagnetically-released, friction brake tobe applied. In the event of over-travel in the hoisting direction, therefore, the motor is slowed down, by dynamic braking or, if: the shunted. motor. hoisting con.- nections. are notv completed, is brought to rest under the combined influence ofv dynamic and friction braking. Insuchprior systems, after the limitswitch has tripped. oroperated to stop the motor, a. series motor lowerin circuitmay be established bymoving amaster switch-to-any of its lowering positions to release the friction brake and enable the-load to-be drivendownwardly out of the limit zone by the motor while the motor is connected as a series machine. Even though the master switch is in the slowest series motor lowering. position, a speedlimiting means such as an armature shunt connection has been foundnecessary on modern hoists equipped with anti-friction bearings to prevent excessive lowering speeds frombeing reached before thelimit switch resets, especially if a heavy overhauling load is being carried by the hoist. As soon as the limit switch resets, the conventional, relativel slow-speed dynamic braking lowering circuit is established causing the motor to slow down suddenly if the series motor speed'is not limited. As a result of such a sudden deceleration, the entire hoisting mechanism is subjected to severe mechanical strains and the motor is apt to have. commutation difficulties. The change of speed is especially great if the master switch is inthe-first or slowest lowering position which, if a heavy load isbeing lowered, is the preferred position, but even if the master switch is in the last or fastestlowering position, the speed change upon resetting of the limit switch is also very large.

The light hook hoisting speeds of modern antifriction bearing cranes are also much greater than the corresponding speeds of oldercranes equipped with sleeve bearings. At the present time, light ho a hoisting speeds of the order of 275 per cent of. rated fullload speed are quite common, and some cranes arebeing operated at speeds as high as,325 per cent of rated full load speed. Since, due to limited hooktravel distance, the excessive hoisting speeds are generally reached only when the emptyhook is approaching the limit switch, and since theduty cycle of many cranes does-not require extremely high light hook hoisting speeds, the excessive hoisting speeds add little ice-the all-day efiiciency of a hoist. However, the increased light hock hoisting speeds of modern anti-friction-hoistsheretofore have made it necessary, in order to'protect the motor from excessive braking currents and voltages, to increase the ohmic value of the dynamic braking resistor in the dynamic braking circuit which is completed by operation of the limit switch when the hook reaches the overhoist limit. Although increasing the dynamicbraking resistance reduces the current and voltage peaks which occur upon the hook entering the limit switch zone at these higher speeds, thereby protecting the motor, the increase in resistance hasserious disadvantages. For example, the increased resistance reduces the amount of braking torque produced at all entering speeds thereby greatly increasing the wear on the friction brake and, unless the limit switch is adjusted to operate at relatively low hook elevations, makes it possible for the hook to strike the drum due to the failure of the brake to set when the motor shunt connection for slow speed hoisting is completed nearly concurrently with the tripping of the limit switch. Normally the motor shunt connection does not present a great hazard since, if the hoist is operating at a slow speed, the reduced dynamic braking torque and the friction of the hoist drive itself are adequate to stop the hook. However, a dangerous condition arises when an empty hook is bein raised at these excessive speeds and approximately at the instant that the limit switch operates the master switch is returned to a position causing completion of the motor shunt circuit. The completed motor shunt circuit prevents the setting of the friction brake, and the dynamic braking and the friction of the hoist drive alone are inadequate to stop the rapidly travelling hook before it strikes the drum.

Another of the disadvantages resides in the fact that since the resistor in the overhoist dynamic braking circuit is connected in parallel with the series connected armature and field windings when the lowering connections are established by the master switch, the increased ohmic value of this resistor causes a correspondingly increased amount of current to flow through the motor resulting in an increased lowering out speed. Consequently, the foregoing disadvantages of the sudden reduction in lowering speed when the limit switch resets are aggravated.

Later prior control systems including means for completing an armature shunt connectionfor the motor while it is lowering a load from the limit switch zone have successfully prevented excessive lowering speeds from being reached. However, all of these later prior systems have required, as additional equipment, an armature shunt resistor along with an extra contact on the limit switch, an extra contactor, or an extra trolley bar and contactor.

In accordance with this invention, there is provided a control system which includes means for completing an armature shunt connection during series motor lowering and which possesses all of the advantages of these later prior systems 'but which does not require the use of such additional equipment except the armature shunt resistor. In addition, a means provided herein for reducing the excessive light load hoisting speeds, thereby permitting the use of an overhoist dynamic braking resistor having a reduced ohmic value, is co-related in accordance with the present invention to the armature shunt connection provided during series motor lowering so as to increase both the effectiveness of the latter and the overhoist dynamic braking action.

It is the general object of this invention to provide a dynamic lowering hoist control system which retains all of the advantages of the usual dynamic lowering hoist control system provided with a dynamic braking type overhoist limit switch and which includes improved means for eliminating any sudden changes in speed which would subject the hoist'meohanism and motor to severe shocks and strains.

More specifically, a principal object is to provide an improved circuit for temporarily connecting a direct current hoist motor as a slow speed machine for lowering operations after a limit switch has been tripped to set up a dynamic braking circuit, and for maintaining said connection effective only until the limit switch resets due to said lowering action.

It is a further object to provide a slow speed series motor lowering connection for lowering a hoist out of an overhoist limit switch zone without requiring the use of an additional electromagnetic switch or relay, or an additional contact on the limit switch.

A more specific object is to provide a slow speed series motor connection in a dynamic braking hoist controller by causing an armature shunt circuit to become effective to limit the lowering speed to a safe value, while lowering out of the limit switch zone, as the result of the opening of one of the usual normally closed contacts of an overhoist limit switch.

Many cranes include a trolley structure on which the hoist motor, electromagnetic brake, limit switch and certain other parts of the hoisting mechanism are mounted. The electromagnetic switch control panel or manual controller is usually mounted on the crane bridge instead of on the trolley structure which moves along the bridge. This arrangement of the hoist apparatus requires connections from the panel or controller to the apparatus on the trolley structure by means of trolley bars and collector shoes. Heretofore, most of such control systems have required four electrically independent trolley bars. Trolley bars are expensive to install, take up valuable space, and are a potential source of trouble. Accordingly, a further object of this invention is to provide, without increasing the number of trolley bars, an improved hoist control system having the foregoing advantages.

In a copending patent application of Asa H. Myles filed on even date. Serial No. 648,952, now abandoned, a dynamic lowering hoist control system including means to reduce the excessive light load hoisting speeds is described and claimed. The use of a means for reducing the excessive light load hoisting speeds permits the use of a lower resistance value in the dynamic braking loop set up by operation of the overhoist limit switch, and thus eliminates the aforementioned disadvantages resulting from the excessive hoisting speeds of modern cranes. It is a still further object of this invention to correlate such a light load speed reducing means with the means for limiting the series motor lowering speed of a dynamic lowering hoist controller so as to improve both the series motor lowering operations of the hoist and dynamic braking.

Other objects and advantages will become apparent from the following specification wherein reference is made to the drawings, in which:

Fig. l is a simplified wiring diagram of the power circuits and the contacts therein, and

Fig. 2 is a simplified wiring diagram of the control circuits'including a master switch and electromagnetic operating means for some of the contacts shown in Fig. 1, and

Fig. 3 is a simple diagrammatic sketch of a crane hoist drive and limit switch operated thereby.

The invention is described herein as embodied in a preferred form of dynamic lowering hoist control system, but it is understood that the invention may be used with other suitable forms of dynamic lowering hoist control systems as well.

Referring principally to Fig. 1, a direct current motor comprising an armature winding it having brush terminals Illa and Illb and a series-type field winding H having terminals Ha and Nb is arranged to be energized from direct current power supply conductors I2 and. I 4: for: raising and lowering of. a load holding device such as a hook I5 (Fig. 3) suspended fromra cabledrum I 6 driven by 'themotor: through suitable gearing. I 8. For operationcf' thermotorinithe hoisting direction, electromagnetic switches. I9 and 2B. are arrangedto connect, through their respective. main contactsIQm-anditm, thearmature winding ID, the fieldwinding I I an operating'winding H of aspring-applied,- electromagnetically-releasedi brake (not shown), and an acceleration and speed -controlling resistor 22 in serieswith each other across the supply conductors I2 and I4. The" brake is'opera'ble :ina well-.known manner to holdthe drum lfi-against-rotation whenever the; winding 2 I- is d'eenergized: and to permit rotation of the drumw-henever thewindingil is energized. For slow speed hoisting-of the hook I 5;.normally spring-closed .ma-in contacts 24m of an electromagnetic sw itchfi licomplete a shunt. circuit for. the motor through a resistor 25 having sections 25a, 25b, and 250.. Increased hoisting speedsare obtained by opening the contacts 24m of the switchM and by seriately closing main contacts 2.6m, 21m, and of. electromagneticaccelerationswitches-ZB, 2i, and 28,.respectively, to short circuit sequentially sections-2.2a and 22b, 22c, and 22d of the resistor 22- fromthemctor circuit.

To protect against raising the hook I5 too closely to the drum It, a limit switch 29 isprovided which maybe any one-of a-number of wellknown dynamic braking types provided. with a pair. ofnormally closed contacts and a pair of normally open contactsi As shown diagrammatically in 3,-the limitswitch 2S--comprises a weight 30. suitably suspended from a counterbalanced lever arm 3 I which is arranged-to actuate an. insulated contact arm 32through a suitable. snap action deviceshown as a coilspring 34. Attachedto. the contact-arm 3ft are the bridging portions. oia pair of. normally closed contacts 29a and.29b and a pair. of: normally. openrcontactsZQc and ZSdwhichpairsof contactsarealso shown diagrammatically in Big. 1. A projecting portion 35 of the hook ihisiarranged.toengage the weight I 30 when the motor lifts the hook idbeyondapredetermined point. Engagement of the-hook portion with the weight 30 releases the lever arm 3| and permits the spring 34 to move the contact arm 32 from the normal left-hand position shown to a right-handposition. This movementof thecontact arm 32 causes opening of the contacts 23a and 29b and closing of the contacts 290 and 29d with a snap action.

Referring again to Fig. 1, opening, of the contacts 29a of the limit switch 29 disconnects thearmature terminal Illa from the supply conductor I2, and opening of the contacts 292) interrupts the usual connection between the armature terminal Iiib and the field terminal Ila. Closure of the contacts 290 and 29d completes a dynamic braking circuit for the motor from the armature terminal IIJa through the contacts 29c'to the field terminal I la where, in accordance with-thepresent invention, the circuit divides. Onebranch of the divided circuit is the usual braking circuit and isthrough the'field winding I I from the terminal Ila to the terminal lib, the contactsi29d, and a resistor 33 to the armature terminal Itbi For purposes later to be described a resistor 313 is connected in parallel with the contacts 2% between the terminals Ifib-and lid and constitutes the other branch of the divided circuit. During lowering operations of the hoist, with the limit switch 29 in its normal, untripped position, the

armaturewinding H1 and the field winding II are tions.

connected; so that the motor. becomes ineffect 1a shunttmachine. Fol-these normal operations of the'motor inthe. lowering direction, main contactsllm of. an electromagnetic switch 40 complete'aconnection from thesupply conductor I2 to the" armature terminal Hlb and through the contacts 29bto'the field terminal I Ia. An armature circuit including thearmature winding I0 extendsto thepower-conductor I4 from the armature terminal iila through all or a portion of theresistor 25, and a field circuit including the field winding; H-extends to the supply conductor I4 from the field terminal I Ib through'the brake winding ll and alior a portion-of the resistor 22,

.. theswitch 2-0 serving'to-complete'the connection from-the right-hand terminal of the resistor 22 to theconductor. Hi; Speed control during-lowering is effected by selective operation of the switches 24, 2?, and z8 and-also by selective operation of electromagnetic switches ii and 42 having main contactsd im and'42m, respectively.

Acceleration. relays may be-used'to delay the closure of the switches 2.! andifi during hoisting operations, and, as-shown, relays and having, normally closed contacts lea and 45a, respectively, are: provided for this purpose. Although any suitable type of acceleration relay may be used, relays M and 45 are prefera'blyof the type described and claimed in T-rofimov PatentNo; 1,980,736, issued'November 13; 1934. A

counter-voltage: acceleration. relay. 46 (Fig. 2) having. normally closed. contacts-45a and normal 1y open contactsd6b is provided for'delaying the closure of the switch z'during lowering opera- As set forth in. said copending application, a resistor- 49 ispreferably connected across the normally open contacts -2 9c of the 'limit switch 29- for limiting the light load hoisting speed in" a manner tobedescribed. Inaccordance-with the present. invention, asexplained more fully hereinafter, .ad-vantageistaken of the inclusion of the resistor M! by correlating it and the resistor 38 provided hereinso. astopermit the use of a lowerohmic value fortheresistor 38., Suchcorrelationresides inselecting the value-of the resistor 49 so that the light hook hoisting speed is adequately reduced andpermitsthe ohmic value of the resistor 3'! to be reduced adequately to. permit theuse ofa lower ohmic value for the resistor 38 without adverse effect on the dynamic braking torque. If desired; the resistors 31, 38, and 49 may he built as a single unit with the necessary intermediate taps.

The motor. the brake winding 2!, the limit switch 29, and the resistors 31, 38, and 49 may be disposed inside of a plurality of trolley wheels andcooperating'trolley bars indicated by the reference characters 5d, 51, 52 and 53. Thus the motor, the brake; the limit switch and the resistors-'31; 38-, and 43 may be mounted on a portion of a crane structure such as a trolley 5 which moves relatively to the remainder of the crane structure upon which the other elements of the control system of Figs. 1 and 2 may be mounted.

In order to lower the-hook I5 while the limit switch is its' tripped position, the contacts 20m and 40m" are closed and a motor circuit is completed from the supply conductor I2 through the contacts item, the armature winding In from the terminal Iilb to the terminal Hla, the limit switch contacts. 290, the field winding II from the" terminal I'Ia to I'll), the brake winding 29, all orapart of the resistor 22, and the contacts 29m to the-supply conductor M. The motor is now connected as a series machine and exerts atorquein thelowering'direction. A shunt cirtremely slow series motor lowering speeds.

cuit around the motor from the armature terminal v[Elli to. the field terminal Hb through the limit switch contacts 29d and the resistor 37 also exists during series motor lowering and reduces the motor torque depending upon the value of the resistor 31. However, if the crane is provided with antifriction bearings and the load on the hook I is relatively large, the speed of the motor may reach excessive values before the limit switch resets even though the resistor 31 has the relatively low value made possible by the use of the resistor 69. The resistor 38, in accordance with this invention, being connected between the terminals [0b and Ma, provides a shunted armature connection which limits thelowering speed to a safe value during lowering operations with the limit switch 29 tripped. It is to be noted that so long as the limit switch is in its tripped position wth the contacts 2% open and the contacts 290 closed, the resistor 38, being permanently connected to the terminals Nib and Ha, is operatively connected in parallel with the armature winding l0 between the terminals Na and Nib. When the limit switch contacts 291) are closed, the resistor 38 is short circuited and thereby rendered completely ineffective so as not to alter normal operations of the hoist.

During dynamic braking occasioned by tripping of the limit switch 29, the resistor 38 is operatively connected in parallel with the armature winding It as above described as well as in parallel with the series connected field winding H and the resistor 3?. The resistor 38 thus shunts some of the dynamic braking current from the.

field winding H and thereby decreases the dynamic braking torque for given values of armature current. Because of magnetic saturation of the field poles, however, it has been found that even when the ohmic value of the resistor 31 is at the usual high enough value required to limit sufil ciently the dynamic braking currents when the resistor 49 is not used, the resistor 38 may have an ohmic value small enough to serve effectively as an armature shunt resistor in lowering out of the limit stop and still not decrease excessively the dynamic braking torque. When the resistor is is used, its ohmic value may be properly correlated with the values of the resistors 3'! and 38 so that the value of the resistor 37 is reduced and in turn, because of the resultant lower resistance of the field branch of the dynamic braking circuit, permits the use of a resistor 33 having a lower ohmic value. A reduced value of the resistor 35, in turn, permits exy this correlation of the resistors 31, 38 and 49, the advantages above described are obtained in addition to those improved dynamic braking advantages resulting from the inclusion of the resistor 29 alone as described in said copending application.

As one example, when the limit switch 29 is in its normal osition and the resistor 49 thereby rendered operative to complete an armature shunt connection, the resistor t9 can be correlated properly with the resistors 3'! and 38 so as to obtain all of these advantages if its ohmic value is such that the maximum empty hook hoisting speed is caused to be between 200% and 250% of full load speed. As set forth in the above copending application, it has been discovered that a resistor 49 of this value, even though operatively connected in parallel with the armature winding Ill during all normal hoisting and lowering operations neither materially alters the speeds obtained when all but extremely light loads are being hoisted at maximum possible speeds nor greatly reduces the intermediate hoisting and all lowering speeds of all loads. The resultant lower light load hoisting speed permits the ohmic value of the dynamic braking resistor 3'! to be reduced without causing the sparking at the motor commutator which would occur if the limit switch were tripped while the motor was operating at the maximum possible hoisting speed obtainable without the use of the resistor 49. Reduction in the value of the resistor 31 increases the effectiveness of the dynamic braking circuit for all hoisting speeds and permits the value of the resistor 38 to be lower than is required when the resistor 49 is not used.

Each of the switches and relays has an operating winding identified by the reference character of the particular switch or relay followed by the subscript w, and, with the exception of the windings 44w and 45w, the switch or relay operating windings are under the control of a m-ulti-position, reversing master switch 54 (Fig. 2) having a lurality of contacts 54a to 54 inclusive. Several of the switches are provided with control circuit contacts which are identified by the reference character of the particular switch followed by a letter subscript such as a, b, or c. All of the master switch contacts are open when the master switch 54 is in the on position illustrated, and are arranged to be closed selectively in the operated positions of the master switch as indicated by the developed showing of the master switch segments. Each of the master switch contacts 54?) to 547' when closed completes a circuit from the power supply conductor l2 through one or more switch operating windings to the supply conductor I4. The contacts 54a when closed complete a circuit for the operating winding 46w from the supply conductor 12 through a conductor 55 to the motor circuit (Fig. 1) between the contacts Him and 29a. The master switch 54 is preferably mounted on the same part of the crane structure as the electromagnetic switches and relays and the resistors 22 and 25.

With the foregoing understanding of the control system elements and their electrical interconnection the operation of the system will become apparent from the following description thereof:

Assuming that the motor is at standstill and the operating winding 2! of the brake is deenergized so that the brake holds the drum l5 against rotation, and further assuming that the remainder of the apparatus is in the normal deenergized positions indicated by the drawing, an emergency dynamic braking circuit is completed (Fig. 1) from the armature terminal Ilia through the contacts 29a, the resistor 25, the contacts 24m, the field winding H from the terminal llb to the terminal Ma, and the contacts 29b to the armature terminal Hlb.

To hoist the hook I 5 at slow speeds, the master switch 54 is moved to its first hoisting position wherein the contacts 541) are closed and complete a circuit from the supply conductor 12 through the winding 281.0 to the supply conductor I 4, and wherein the contacts 541' are closed and complete a circuit from the conductor l2 through the winding 99w to the conductor M. Energization of the windings i920 and 2%) causes closure of the contacts Him and 20m to complete a circuit (Fig. 1) extending from the conductor IZ'through the contacts Him, the contacts 29a,

the armature winding 1-0, the contacts 29?), the field winding H, the brake winding 2!, the resistor 22 and the contacts 20m to the conductor M. The circuit through the resistor 25 and the contacts 24m remains completed while the master switch is in the first hoisting position to provide a slow-speed, motor shunt connection, and the current flowing through the brake winding 2! releases the brake.

Increased hoisting speeds are obtained upon movement of the master switch 54 to the second hoisting position wherein the contacts 542' are closed and complete a circuit from the conductor H to the conductor M through .a conductor .53, the Winding 25w, and the contacts ifia which closed upon energization of the winding iiiw. Energization of the winding 2 5w causes opening of the contacts Mm which interrupts the motor shunt circuit through the resistor 25 th reby causing an increase in the motor speed. Closure of the contacts Meand opening of the contacts 240. resulting from the energization of the winding 24w have no effect at this time, .but closure of the contacts 2% partially completes a circuit from the conductor iii to the windinglfiw. .In event that the switch t l-fails to operate for any reason upon energization of the winding 24w, the consequent failure of the contacts 2% to close renders subsequent energization ofthe winding Zl-w impossible thereby to prevent acceleration of themotor to its normal speed.

A iurther increase .in hoisting speed is obtained :by moving the master switch to the third hoisting .position wherein the contacts 5 50 are closedand complete an obvious energizing circuit for the winding 26w. Energization of the winding 26w causes closure of the contacts 26a in the circuit ofthe winding N10 and causes closure of the contacts 26m which when closed short circuit the resistor sections 22a and 22b. The current flowing around the resistor sections 22a and 2% through the contacts 26m energizes the winding 154w and causes opening of the contacts Add .in the energizing circuit of the winding film for a time interval dependent upon the magnitude of the current flowing through the winding 4420 during the interval as described in the above mentioned Trofimov patent.

When the master switch is in the fourth hoisting position, the contacts Fi -id are closed and complete a circuit from the conductor i2 through the winding 2720 'to' the conductor it provided that the contacts 44a, Ziia and 2 1) interposed in the circuit are all closed. Energization of the winding 21w causes closure of the contacts 21m to short circuit the resistor section 220 and also causes closure of the contacts 2la in an energizing' circuit for the winding 28w. Upon closure of the contacts Elm the motor current flowing therethrough causes energization of the winding of the relay 4-5 which thereupon open the contacts 45a in the energizing circuit for the winding 25w for a time interval as in the case of the relay it.

If the master switch is now moved to the fift hoisting position, the contacts 5t) close and complete the energizing circuit for the winding 2%!) depending upon the prior closure of the contacts 45a and 21a. Closure of the contacts 28m upon energization of the winding 28w short circuits the remainder of the resistor 22 so that the hoist motor is now connected directly across the power supply conductors l2 and Hi.

The operation of the resistor 43 at all times during hoisting While the limit switch 29 is in its normal untripped position is follows:

The resistor 43 is operatively connected in parallel with the armature winding iii, thereby causing the current in the field winding ii to be slightly higher than it would be if the resistor 4.9 were not so connected. The resistor 49 preferably has an ohmic value such that so long as the motor is hoisting a considerable load or so long as some of the acceleration resistor 22 is in the motor circuit, the speed of the motor is not greatly decreased by the presence of the resistor 49. If the motor is subjected to a very light load such as merely lifting the hook it when empty, however, and the resistor 22 is all short circuited, the motor speed with the resistor 49 connected is much less than it would be if the resistor as were not connected in the motor circuit. Exemplary ohmic values for the resistor 19 in order to accomplish the desired result of limiting the maximum light load hoisting speed to a desirable speed for dynamic braking action without materially reducing other hoisting speeds are between six and ten times the quotient obtained by dividing the rated voltage of the motor by the full load current of the motor in amperes. A resistor so selected can be properly correlated with the resistors 31 and 38. When the resistor 49 is used, the ohmic value of the resistor 37 in the dynamic braking circuit may be as low as 50% of the quotient obtained by dividing the rated motor voltage by the full load motor current in amperes since, if an empty hook is hoisted into the limit switch zone with all of .the resistor 22 out of the motor circuit, the resistor 49 limits the speed to a low enough value to permit proper and safe commutation of the braking current. If the resistor i9 is not used, the resistance of the resistor ill would have to be in the neighborhood of of the voltage-armature current quotient for proper oommutation.

If the hook it is hoisted high enough so that the limit switch is tripped, the contacts 29a and 2% open to disconnect the motor from the power conductor I2 and the contacts 2810 and 29d close to complete the previously traced emergency dynamic braking circuit. Closure of the contacts 290 short circuits the resistor 49 and renders it completely inoperative during the braking period as well as while the hook is being lowered out of the limit switch zone.

Power lowering or dynamic braking lowering of the hook IS with the limit switch 29 in its normal position is accomplished by moving the master switch 54 to any one of the lowering positions. Upon movement of the master switch to the first lowering position, the windings 2610, 2120, 23w, and Min: of the switches 20, 2'1, 28 and 45, respectively, are energized concurrently. The energizing circuit for the winding 20w is completed from the supply conductor [2 through the contacts 54b, and the energizing circuit for the winding 21w is completed through the contacts 54c and a conductor 53. The energizing circuit for the winding 40w is completed through the contacts 5471., and the circuit to the winding 28w is initially completed through the contacts Edit and the normally closed interlock contacts 24a interposed in a conductor El thereby insuring operation of the switch 28 concurrently with operation of the switches 28, 2'1, and '49. Aftercperation of the switch 21, due to energization of its winding 21w, a circuit through the contacts 549, a conductor 58, and the interlock contacts 27a is completed and becomes operative upon subsequent opening of the contacts 24a to continue the ener-" gization of the winding 28w. Energization of the windings Zilw, 21w, 28w, and 40w results in closure of the contacts 26m, 21m, 28m, and 40m to connect the motor in a slow-speed dynamic lowering circuit. With the lowering contacts 48m closed, a circuit is completed from the supply conductor I2 through the contacts 40m to the armature terminal Hlb where the circuit divides into parallel connected armature and field circuits. The armature circuit with the master switch in the first lowering position is from the armature terminal lflb through the armature winding ill to the armature terminal Illa, and thence through the contacts 25a, all of the resistor 25, and the contacts 24m to the field terminal Ill), and the corresponding field circuit extends from the armature terminal lEib through the contacts 2% and the field winding H from the field terminal Ha to the field terminal lib. From the field terminal I lb the first point lowering motor circuit is completed through the brake winding 2|, the contacts 28m, the coil 44w (the relay 44 is inefiective during lowering, however), the resistor sections 22b and 22a, and the contacts 20m to the supply conductor I4. With the foregoing motor circuit completed, a very slow lowering speed is obtained for all loads.

An increased lowering speed for light as Well as heavy loads is obtained upon movement of the master switch 54 to the second lowering position. Upon closure of the master switch contacts 541' in the second lowerin position, an energizing circuit for the winding 4110 is completed through a conductor 59, the winding Mw, the contacts 42a and 46a in parallel witheach other, and the contacts 48a, which closed upon energization of the winding 4820. The contacts 4!?) close upon energization of the winding 4lw to complete a circuit through the contacts 541', the conductor 53, the winding 24w, the contacts Mb, and a conductor 6| to the contacts Add. This sequential energization of the windings Mw and 2420 results in closure of the contacts 'lllm followed by opening of the contacts 24m. The armature circuit now extends through sections 250 and'25b of the resistor 25 and the contacts 4lm to a junction point 22' on the resistor 2210ctween the sections 220. and 22b, and the field circuit now extends through the'brake winding 2!, the contacts 28m, the winding 44w, and the resistor section 2% to the junction point 22' from whence the motor circuit is completed to the supply conductor l4 through the resistor section 22a, and the contacts 20m. Energization of the winding 24w also results in closure of the contacts, 240 in the energizing circuit for the winding 4610, in closure of the contacts 24b which serve no function during lowering, and opening of the contacts 24a to interrupt the circuit to the winding 28w through the conductor A further increase in the lowering speed is obtained upon movement of the master switch 54 to the third lowering position wherein .the contacts 54g are open resulting in deenergization of the winding 28w since the contacts 240, opened upon operation of the switch 24. Opening of the contacts 28m consequent upon deenergization of the winding 28w inserts the resistor section 22d into the field circuit which now extends from the armature terminal lllb through the contacts 2%, the field winding l I, the brake winding 2 l the resistor 22d, the winding 4510 (the relay45 is inefiective in lowering, however), the contacts 21m,

12 the winding 44w, and the resistor section 2% to the junction point 22'.

Movement of the master switch 54 to the fourth lowering position results in a further increase in lowering speeds due to the opening of the contacts 21m consequent upon deenergization of the winding 21w resulting from opening of the contacts 54c. The field circuit now includes the resistor sections 2212, 22c, and 2201. It should he noted that the armature circuit remains the same in the second, third, and fourth lowering positions.

Movement of the master switch 54 to the fifth lowering position causes closure of the contacts 54a to connect the winding 46w across the armature winding If). The circuit for the winding 4610 is from the armature terminal lfib, the contacts 40m, the supply conductor [2, the contacts 54a and 24a, the winding 4610, the conductor 55, and the contacts 25m, to the armature terminal Illa. The contacts 240 are included in this circuit to prevent premature operation of the relay 46 if the master switch is moved rapidly to the fifth lowering position while the motor is operating in the hoisting direction. As soon as the countervoltage of the armature reaches a predetermined value, the winding 46w is operatively energized to open the contacts 46a and to close the contacts 461). Opening of the contacts 48a interrupts one circuit for the winding 4 Iw, and closure of the contacts 46b completes an energizing circuit for the winding 42w from the contacts 542' through a conductor 62, the winding 42w, and the contacts 46b, to the contacts 400,. Energization of the winding 4211) results in closure of the contacts 42m and 42b and opening of the contacts 42a. Opening of the contacts 42a opens the only remaining energizing circuit for the winding M10 and the switch 4| drops out to open the contacts 41m and 4 lb and to close the contacts 4 la. Opening of the contacts 4 lb interrupts one circuit for the winding 2410, but the winding 24w remains energized through the contacts 19b and 42b. Sequential closing of the contacts 42m and opening of the contacts 4 lm consequent upon sequential energization of the winding 4220 and deenergization of the winding 4Iw causes the field circuit now to include all of the resistor 22 and the armature circuit to include only the resistor section 250 with no resistance in series with both the armature and field circuits. Themotor now operates at its fastest stable speed in the lowering direction.

The resistor 49 is connected across the armature winding It at all times during lowering so long as the limit switch 29 is in its normal position, but the relatively high resistance of the resistor 49 as described above prevents its connection in the circuit from having but little appreciable effect on the lowering speeds.

Movement of the master switch from the higher to the slower lowering speed positions or to the oiT position results in sequential operation of the switches opposite from that just described for lowering acceleration. In order to insure that the armature circuit is notopened during lowering deceleration, the winding 4 l w is energized through the contacts 48a upon drop-out of the relay 4t and the winding 42w remains energized after opening of the contacts 46b through a, circuit including the contacts 41a and 422); Although the windings 41w and 2410 are deenergized, concurrently in moving the master switch from the second to the first lowering position, the contacts 24m due to their spring'rbia's close before the contacts Mm open.

If the hook has been hoisted high enough to operate the limit switch 29 from its normal position, lowering is accomplished by moving the master switch into any-of the lowering positions which results in the same sequence of switch operation as described for normal lowering operations and also efiects connection of the'motor as a series machine exerting a downward torque. With the :limit switch-29 tripped, closure of the contacts 43m and m completes a motor circuit from the supply conductor 12 through the contacts Him, the armature winding lo, the now closedcontacts 290, the field winding from the terminal I la to lib, the brake winding 2|, part or all of the resistor 22 dependin upon the masterswitch position, and the contacts 20m to the supply conductor [4. If the master switch is in the first or the second position, the contacts 28m and 27m are closed to shunt the resistor sections 2211 and 220.

As described for normal lowering operations, the switch 28 opens its contacts 28m when the master switch is moved to the third loweringposition and'the switch 21' opens its contacts 21m when the master switch is moved to its fourth lowering position. So long as the limit switch is tripped, operationof the switches 24, AI, and 42 has no effect since the contacts 29a are open. Opening of each of the contacts 28m and 21m results man-increase in resistance in series with the motor. The motor shunt circuit from the armature terminal ltb through the resistor 31 and the contacts 29d to the terminal l-lb is completed when lowering with the limit switch tripped and the armature shunt circuit through the resistor 38 is operative at this timesince the contacts 29?) are open. The armature shunt circuit, including the resistor 38, causes the motor to exert dynamic braking torque if the load is overhauling so that the lowering speed does not become excessive before the limit switch resets. Since the resistor 38 is permanently connected, as shown,, across the contacts 291), it is rendered operative and inoperative directly-by one of the usual limit switch contacts without the use of additional contactors or relays or special limit switch contacts. It has been found after exhaustive tests that the value of the resistor 38 may be made low enough to provide the desired slow speed lowering withoutmaterially reducing the dynamic braking torque upon the hook entering the limit switch zone even if the resistor 31 has the high value often required when light hook hoisting speeds can reach 300% of full load speed. The'fact that the ohmic value of the resistor 31 may be reduced by provision of the resistor 49, however, permits greater freedom in selection of higher or lower values of the resistor 38 depending upon the relation between braking torque and series motor lowering speed desired in any particular case. For example, the resistor 38, for best speed limiting effects, has an ohmic value within the range of 30% to 50% of the quotient obtained by dividing the rated or operating voltages of the motor by the full load current of the motor in amperes.

I claim: I

1. In a motor and control system combination for raisin and lowering a load, a direct current motor adapted for connection'to a'source of power and having-an armature winding and a field winding, which windings are adapted for shunt and series connection, selectively, with-each other, for operation of=the motor as a shunt and series machinegs'electively a limit switch mechanism hav- 14 ing a normally closed contact means connected between a first terminal of said armature winding and a first terminal of said field winding and having a, normally open contact means connected between a second terminal of saidarmature winding and said first terminal of said field winding, and being responsive to an elevated position of the load while the load is being raised to open said normally closed contact means and to close said normally open contact means, means for connecting a second terminal of said field windin to one side of said source of power, means for connecting said second terminal of said armature winding to the other side of said source of power for hoisting a load, and means for connecting said first terminal of the armature winding to said other side of said source of power for lowering a load when the second field terminal is connected to said one side of said source of power and while said normally closed contact means is open and said normally open contact means is.

contact means is closed and until said normally.

closed contact means recloses.

2. In a control system for raising and lowering a load by adirect current motor adapted for connection to a source or power and having an armature winding and a field winding of the series type normally disconnected from the armature winding, the combination with an acceleration resistor, a limit switch mechanism including a first contact means adapted to complete, when closed, a first connection between a first terminal of the armature winding and a first terminal of the field winding, said limit switch including additional contact means adapted to complete, when closed, a second connection between a second terminal of the armature winding and said first field ter-- minal, a hoisting switching means adapted to connect saidsecond armature terminal to one side of said source of power and completing through said first connection a hoisting circuit for the motor with the motor connected as a series machine, said limit switch mechanism being operative consequent upon the load being raised to a predetermined elevated position to effect concurrently disconnection of the motor from said source, openingof s id first contact means thereby to interrupt saidnrstconnection, and preparation of the motor for reverse operation as a series machine for lowering the load completing said secondconnection, and lowering switching means adapted to connect said first armature terminal to said one side of said source of power and com pleting, when closed, a lowering circuit for the motor through said connection and said acceleration resistor with said motor connected as a series machine, of a speed limiting resistor connected in parallel with said first contact means so as to be connected between said first armature terminal and said first field terminal and operative in cooperation with said acceleration resistor to limit the speed of the motor during lowering operation, said limit switch mechanism being operative consequent upon the load being lowered to a predetermined position to reclose said first contact means thereby to re-complete said first connection and to render said speed limiting resistor inoperative.

3. In an electric motor and control system combination for raising and lowering a load, a direct current motor adapted for connection to a source of power and having an armature winding and a field winding of the series type normally disconnected from the armature winding, an acceleration resistor, a limit switch mechanism including a first contact means completing, when closed, a first connection between a first terminal of the armature winding and a first terminal of the field,

winding, said limit switch including additional contact means completing, when closed, a second connection between a second terminal of the armature winding and said first field terminal, I

reverse operation as a series machine for lowering the load by completing said second connection, and lowering switching means, when closed, connecting said first armature terminal to said one side of said source and completing a lowering circuit for the motor through said second connection and said acceleration resistor with said motor connected as a series machine, of an armature shunt resistor connected in parallel with said first contact means and connected between said first armature terminal and said first field terminal and operative in cooperation with said acceleration resistor to limit the speed of the motor during lowering operation, said limit switch mechanism being operative consequent upon the load being lowered to a predetermined position to reolose said first contact means thereby to re-complete said first connection and to render said armature shunt resistor inoperative.

4. The combination according to claim 3 further characterized in that said armature shunt resistor has an ohmic value of from 30% to 50% of the quotient obtained by dividing the rated voltage of the motor by the full load current of the motor in amperes.

5. The combination with a motor control system for a hoist including a direct current motor having an armature winding and a field winding, which windings are adapted for shunt and series connection, selectively, with each other across a source of power, for operation of the motor as a shunt and series machine, selectively, to raise and lower various loads which, while being raised,

subject the motor to a loading which ma vary from near zero to rated full load, means for connecting said armature windin and said field winding in a series circuit with each other across the source of power for hoisting a load which may be so small as to permit said motor to operate at an excessive speed, a dynamic braking resistor, and limit means having a normally closed contact means interposed in said series circuit between a first armature terminal and a first field terminal and having a pair of normally open contact means, one or which is interposed in a circuit between a second armature terminal and said first field terminal and the other of which is interposed in a' circuit between said first armature terminal and a second field terminal in series with said dynamic braking resistor, said limit means being operable at a predetermined elevated position of said load to open said normally closed contact means and to close said normally open contact means for reconnecting said armature winding and field winding to each other in a dynamic braking loop circuit with said dynamic braking resistor, said dynamic braking resistor having an ohmic value insufiicient to limit the dynamic braking current, if said limit means operates while said motor-is operating at said excessive speed, to a value below the commutation limit of said motor for such braking service, of means operative, when said small loads are bein hoisted, for limiting the maximum hoisting speed of said motor to a value such that said dynamic braking resistor has a sufficient ohmic value to limit the dynamic braking current to a value below said commutation limit, a speed limiting resistor effectively connected, upon operation of the limit switch, in shunting relation to said armature winding bet-ween said first and second armature terminals, an acceleration resistor, and switching means operable, while said limit means is operated, for connecting said motor as a series machine across the source of power in series with said acceleration resistor for lowering a load at a speed limited by cooperation between said speed limiting resistor and said acceleration resistor.

6. An electric motor and control system combination in accordance with claim 1 characterized in that a dynamic braking resistor is provided, said limit switch mechanism having a second normally closed contact means interposed between said second armature terminal and said means for connecting said second armature terminals to the power source, said limit switch mechanism having a second normally open contact means connecting said second terminal of said field winding through said dynamic braking resistor to said first terminal of said armature winding, and said limit switch mechanism being operative to close and open said second normally closed contact means with said first normally closed contact means and to close and open said second normally open contact means with said first normally open contact means.

7. A control system in accordance with claim 2 characterized in that a dynamic braking resistor is provided, said limit switch includes further contact means adapted to complete, when closed, a circuit from a second field terminal of the motor to said first armature terminal through said dynamic braking resistor, and said limit switch mechanism is operative to close and open said further contact means with said additional contact means.

' 8. An electric motor and control system combination in accordance with claim 4 characterized in that a dynamic braking resistor is provided, said limit switch mechanism includes further contact means completing when closed a circuit from a second field terminal to said first armature terminal through said dynamic braking resistor, said limit switch mechanism is operative to close and ,open said further contact means with said additional contact means, and said dynamic braking resistor has an ohmic value in the neighborhood of of said quotient.

9. The combination in accordancewith claim 5 r e e n th he mea s perative to:

17 limiting the maximum hoisting speed of the motor is a resistor operatively connected between said second armature terminal and said first field terminal when said motor is connected for hoisting a load.

HAROLD J. RATHBUN.

REFERENCES CITED The following references are of record in the file of this patent:

Number 18 UNITED STATES PATENTS Name Date Palmer June 9, 1914 Hart Oct. 13, 1914 Wright Oct. 13, 1914 Cooke June 10, 1941 

